Give me your common5.pac from the pf/system folder and I'll check it out. (that file has all the portraits)
I had similar issues earlier. There are so many awesome ways to make Smash crash. I'm having a few occasional (random) crashes sometimes with my build, for whatever reason, on game loading after stage select. I spent like 2 weeks making portraits and renders, a lot of that time learning what makes this **** crash, and I've added so much nice stuff, but now it's crashy.
I'll list some things that make it crash:
-Portrait is too wide of a proportion (not 100% sure about this one)
-Portrait is too big.
-The total size of the sc_selcharacter_en in the common5.pac file exceeds 3.71 MB. To make your images smaller, I delete portrait using BrawlBox, then do right-click>Import>Texture and add it back to the MiscData folder for the character, then set the compression to CMPR, which will reduce the size.
-Putting a file in a character's Miscdata folder without giving it a name like MenSelchrFaceB.011
Putting something like MenSelchrFaceB.021 in the Donkey Kong folder when his portraits only go up to 20.
Miscdata folder for a character not being set at the proper file Index -
http://i.imgur.com/JOpZiUF.png (Note that FileIndex is 1 for MiscData[1])
-Deleting and then importing someone else's char_bust_tex_lz77 (a pac file within the sc_selcharacter_en that contains all the portraits) will probably crash the folder. It's better to right-click on char_bust_tex_lz77 and hit "replace" when putting in portraits.
-Accidentally renaming your char_bust_tex_lz77 folder. I inadvertently did this by deleting and importing a file and didn't fix the name or something.